Polymer particle and method for producing the same

ABSTRACT

A method for producing polymer particles, including (A) polymerizing and granulating a ring-opening polymerizable monomer in a compressive fluid with a catalyst in the presence of a surfactant, or (B) polymerizing and granulating an addition polymerizable monomer in a compressive fluid in the presence of a silicone surfactant.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for producing polymerparticles in a compressive fluid through heterogeneous polymerization ofa ring-opening polymerizable monomer or through polymerization of anaddition polymerizable monomer; and to polymer particles obtained by themethod.

2. Description of the Related Art

Well known are methods of producing fine polymer particles throughheterogeneous polymerization of a monomer in supercritical carbondioxide, including emulsion polymerization, dispersion polymerizationand suspension polymerization.

Heterogeneous polymerization in supercritical carbon dioxide has thefollowing advantages over heterogeneous polymerization in water ororganic solvents, and thus is utilized as a method for producing finepolymer particles from various monomers. The obtained polymer particlesare used for various applications such as electrophotographicdevelopers, printing inks, building paints and cosmetics. Specifically,the advantages are as follows.

(1) Solvent removal and drying after polymerization can be simplified.(2) Treatment of waste solvent can be omitted.(3) Highly toxic organic solvent is not needed.(4) Residual unreacted monomer components and hazardous materials can beremoved at a washing step.(5) Used carbon dioxide can be recovered and recycled.

For example, Japanese Patent Application Laid-Open (JP-A) No.2009-167409 discloses a method of synthesizing colored polymer particlesfrom a radical polymerizable monomer in the presence of a surfactantcontaining a perfluoroalkyl group. However, the fluorine-containingsurfactant used in this method is very expensive and also is problematicin terms of safety. Further, this method cannot produce polymerparticles having a small molecular weight distribution (Mw/Mn) (about 2or smaller) attained by the present invention.

JP-A No. 2009-132878 discloses a method of producing polymer particlesusing a polymer radical polymerization initiator containing anorganosiloxane skeleton, while synthesizing a polymer surfactant in onepot without separately synthesizing and preparing surfactants suitablefor monomers. However, this method also cannot produce polymer particleshaving a molecular weight distribution (Mw/Mn) of 2 or less. Further,there is no description about ring-opening polymerizable monomers.

As described above, no reports have been presented on a method forproducing polymer particles having a small molecular weight distributionwith an inexpensive, highly safe means using a ring-openingpolymerizable monomer or an addition polymerizable monomer in acompressive fluid such as a supercritical fluid.

BRIEF SUMMARY OF THE INVENTION

The present invention aims to provide a method for efficiently producingpolymer particles with narrow molecular weight distribution from aring-opening polymerizable monomer in a compressive fluid in thepresence of a surfactant, and polymer particles obtained by this method.

Also, the present invention aims to provide a method for efficientlyproducing polymer particles with narrow molecular weight distributionfrom an addition polymerizable monomer in a compressive fluid in thepresence of a silicone surfactant, and polymer particles obtained bythis method.

Means for solving the above existing problems are as follows.

<1> A method for producing polymer particles, including:

(A) polymerizing a ring-opening polymerizable monomer to produce apolymer while granulating the polymer in a compressive fluid with acatalyst in the presence of a surfactant, or

(B) polymerizing an addition polymerizable monomer to produce a polymerwhile granulating the polymer in a compressive fluid in the presence ofa silicone surfactant.

<2> The method according to <1>, wherein the catalyst is an organiccatalyst.

<3> The method according to <2>, wherein the organic catalyst is anucleophilic nitrogen compound having basicity.

<4> The method according to <2>, wherein the organic catalyst is acyclic compound containing a nitrogen atom.

<5> The method according to <2>, wherein the organic catalyst is atleast one selected from the group consisting of a cyclic amine compound,a cyclic diamine compound, a cyclic triamine compound having a guanidineskeleton, a heterocyclic aromatic organic compound containing a nitrogenatom and N-heterocyclic carbene.

<6> The method according to <5>, wherein the organic catalyst is any oneselected from the group consisting of 1,4-diazabicyclo-[2.2.2]octane,1,8-diazabicyclo[5.4.0]undec-7-ene, 1,5,7-triazabicyclo[4.4.0]dec-5-ene,diphenylguanidine, N,N-dimethyl-4-aminopyridine, 4-pyrrolidinopyridineand 1,3-di-tert-butylimidazol-2-ylidene.

<7> The method according to <1>, wherein the ring-opening polymerizablemonomer is a lactide of L-form lactic acids, a lactide of D-form lacticacids, or a lactide of an L-form lactic acid and a D-form lactic acid.

<8> The method according to <1>, wherein the surfactant used in (A) hascompatibility to both the compressive fluid and the ring-openingpolymerizable monomer.

<9> The method according to <1>, wherein the surfactant used in (A)contains any one selected from the group consisting of a perfluoroalkylgroup, a polydimethylsiloxane group and a polyacrylate group.

<10> The method according to <1>, wherein the silicone surfactant usedin (B) is a surfactant represented by General Formula (1), (2) or (3)below:

where Me denotes a methyl group; one or two among R¹, R² and R³ eachrepresent a residue containing a C6-C30 long-chain alkyl group and theother or the others each represent a residue containing a C1-C4 loweralkyl group; and each of m and n is an integer of 1 or greaterindicating a number of repeating units,

where Me denotes a methyl group, R⁴ and R⁶ each represent a hydrogenatom or a methyl group, R⁵ represents a methylene group or an ethylenegroup, and each of m and n is an integer of 1 or greater indicating anumber of repeating units,

where at least one of R⁷ and R⁸ represents a residue containing a C6-C30long-chain alkyl group and the other represents a residue containing aC1-C4 lower alkyl group; R⁹ to R¹³ each represent a hydrogen atom or aC1-C4 lower alkyl group; and each of m and n is an integer of 1 orgreater indicating a number of repeating units.

<11> The method according to <1>, wherein the compressive fluid isformed of carbon dioxide.

<12> Polymer particles obtained by a method including:

(A) polymerizing a ring-opening polymerizable monomer to produce apolymer while granulating the polymer in a compressive fluid with acatalyst in the presence of a surfactant, or

(B) polymerizing an addition polymerizable monomer to produce a polymerwhile granulating the polymer in a compressive fluid in the presence ofa silicone surfactant.

<13> The polymer particles according to <12>, wherein the polymerparticles have a molecular weight distribution Mw/Mn of 2.0 or less,where Mw denotes a weight average molecular weight of the polymerparticles and Mn denotes a number average molecular weight of thepolymer particles.

The present invention can provide a method for efficiently producingpolymer particles with narrow molecular weight distribution from aring-opening polymerizable monomer in a compressive fluid in thepresence of a surfactant, and polymer particles obtained by this method.

Also, the present invention can provide a method for efficientlyproducing polymer particles with narrow molecular weight distributionfrom an addition polymerizable monomer in a compressive fluid in thepresence of a silicone surfactant, and polymer particles obtained bythis method.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a general phase diagram showing the state of a substancevarying depending on pressure and temperature conditions.

FIG. 2 is a phase diagram which defines a compressive fluid used in thepresent invention.

FIG. 3 is an electron microscope image showing the aggregation state ofpolymer particles A1.

FIG. 4 is an electron microscope image of each of polymer particles A1.

FIG. 5 is an image obtained by photographing polymer particles A1 with adigital camera.

FIG. 6 is an image obtained by photographing an aggregated polymer ofComparative Example A1 with a digital camera.

DETAILED DESCRIPTION OF THE INVENTION

In a first embodiment, the present invention has a technical feature ofpolymerizing a ring-opening polymerizable monomer simultaneously withgranulating the resultant polymer (particle formation) in a compressivefluid. The present invention first discloses the granulation of polymersusing the ring-opening polymerizable monomer in the compressive fluid.

In a second embodiment, the present invention has a technical feature ofpolymerizing an addition polymerizable monomer simultaneously withgranulating the resultant polymer (particle formation) in a compressivefluid. In addition, the present invention has another technical featurethat a silicone surfactant used is inexpensive and highly safe and theproduced polymer particles have a narrow molecular weight distribution.

In the present invention, the “compressive fluid” refers to a substancepresent in any one of the regions (1), (2) and (3) of FIG. 2 in thephase diagram of FIG. 1. In FIGS. 1 and 2, Pc and Tc denote a criticalpressure and a critical temperature, respectively.

In such regions, the substance is known to have extremely high densityand show different behaviors from those shown at normal temperature andnormal pressure. Notably, the substance present in the region (1) is asupercritical fluid. The supercritical fluid is a fluid that exists as anoncondensable high-density fluid at a temperature and a pressureexceeding the corresponding critical points, which are limiting pointsat which a gas and a liquid can coexist. Also, the supercritical fluiddoes not condense even when compressed, and exists at a criticaltemperature or higher and a critical pressure or higher. Also, thesubstance present in the region (2) is a liquid, but in the presentinvention, is a liquefied gas obtained by compressing a substanceexisting as a gas at normal temperature (25° C.) and normal pressure (1atm). Further, the substance present in the region (3) is a gas, but inthe present invention, is a high-pressure gas whose pressure is ½ Pc orhigher.

Examples of the substance usable as the compressive fluid include carbonmonoxide, carbon dioxide, dinitrogen monoxide, nitrogen, methane,ethane, propane, 2,3-dimethylbutane and ethylene. These may be usedalone or in combination.

Among them, carbon dioxide is preferred, since its critical pressure andtemperature are about 7.4 MPa and about 31° C., it can be easily broughtinto a critical state, and it is nonflammable to allow easy handling.

Also, when carbon dioxide is used as the compressive fluid, thetemperature is preferably 25° C. or higher and the pressure ispreferably 5 MPa or higher, considering the reaction efficiency, etc.More preferably, supercritical carbon dioxide is used.

The pressure upon polymerization; i.e., the pressure of the compressivefluid, is preferably a pressure at which the compressive fluid isbrought into a supercritical state, in order to increase dissovabilityof the monomer into the compressive fluid and make the polymerizationreaction to proceed uniformly and quantitatively, although thecompressive fluid may be high-pressure gas or liquefied gas. When carbondioxide is used as the compressive fluid, the pressure must be 3.7 MPaor higher, preferably 5 MPa or higher, more preferably 7.4 MPa (criticalpressure) or higher.

<Ring-Opening Polymerizable Monomer>

The ring-opening polymerizable monomer which can be polymerized in thepresent invention is not particularly limited so long as it contains anester bond in the ring. Examples thereof include cyclic esters andcyclic carbonates.

The cyclic esters are not particularly limited and may be those known inthe art. Particularly preferred monomers are, for example, cyclic dimersobtained by dehydration-condensating L-form compounds with each other,D-form compounds with each other, or an L-form compound with a D-formcompound, each of the compounds being represented by General Formula α:R—C*—H(—OH)(COOH) where R represents a C1-C10 alkyl group.

Specific examples of the compound represented by General Formula αinclude enantiomers of lactic acid, enantiomers of 2-hydroxybutanoicacid, enantiomers of 2-hydroxypentanoic acid, enantiomers of2-hydroxyhexanoic acid, enantiomers of 2-hydroxyheptanoic acid,enantiomers of 2-hydroxyoctanoic acid, enantiomers of 2-hydroxynonanoicacid, enantiomers of 2-hydroxydecanoic acid, enantiomers of2-hydroxyundecanoic acid, and enantiomers of 2-hydroxydodecanoic acid.Of these, enantiomers of lactic acid are particularly preferred sincethey have high reactivity and are easily available. The cyclic dimersmay be used alone or in combination.

The other cyclic esters than those represented by General Formula αinclude aliphatic lactones such as β-propiolactone, β-butyrolactone,γ-butyrolactone, γ-hexanolactone, γ-octanolactone, δ-valerolactone,δ-hexanolactone, δ-octanolactone, ε-caprolactone, θ-dodecanolactone,α-methyl-γ-butyrolactone, β-methyl-δ-valerolactone, glycolide andlactide. Of these, ε-caprolactone is particularly preferred since it hashigh reactivity and is easily available.

Also, non-limiting examples of the cyclic carbonates include ethylenecarbonate and propylene carbonate.

The ring-opening polymerizable monomers may be used alone or incombination. The obtained polymer preferably has a glass transitiontemperature equal to or higher than room temperature. When the glasstransition temperature is too low, the polymer cannot be recovered asparticles in some cases.

In polymerizing the ring-opening polymerizable monomer, any of a metalcatalyst and a metal-free organic catalyst can be used. Considering theinfluence on the environment, an organic catalyst is preferably used.The organic catalyst may be any catalysts so long as they act onring-opening reaction of the ring-opening polymerizable monomer to forman active intermediate together with the ring-opening polymerizablemonomer and then are removed (regenerated) through reaction with analcohol. The polymerization reaction proceeds even using a cationiccatalyst. However, the cationic catalyst pulls hydrogen atoms out fromthe polymer backbone (back-biting). As a result, the produced polymerhas a broad molecular weight distribution and also,high-molecular-weight polymers are difficult to obtain. Thus, preferredare compounds having basicity and serving as a nucleophilic agent. Morepreferred are cyclic compounds containing a nitrogen atom. Examples ofthe compounds include cyclic amines, cyclic diamines (cyclic diaminecompounds having an amidine skeleton), cyclic triamine compounds havinga guanidine skeleton, heterocyclic aromatic organic compounds containinga nitrogen atom and N-heterocyclic carbenes.

Examples of the cyclic amine include quinuclidine. The cyclic diamine isnot particularly limited and may be appropriately selected depending onthe intended purpose. Examples of the cyclic diamine include1,4-diazabicyclo-[2.2.2]octane or DABCO and1,5-diazabicyclo(4,3,0)nonene-5. Examples of the cyclic diamine compoundhaving an amidine skeleton include 1,8-diazabicyclo[5.4.0]undec-7-ene orDBU and diazabicyclononene. Examples of the cyclic triamine compoundhaving a guanidine skeleton include 1,5,7-triazabicyclo[4.4.0]dec-5-eneor TBD and diphenylguanidine or DPG. Examples of the heterocyclicaromatic organic compound containing a nitrogen atom includeN,N-dimethyl-4-aminopyridine or DMAP, 4-pyrrolidinopyridine or PPY,pyrrocolin, imidazole, pyrimidine and purine. Examples of theN-heterocyclic carbene include 1,3-di-tert-butylimidazol-2-ylidene orITBU. Of these, DABCO, DBU, DPG, TBD, DMAP, PPY and ITBU areparticularly preferred.

The type and the amount of the organic catalyst used cannot flatly bedetermined since they vary depending on combinations of the compressivefluid and the ring-opening polymerizable monomer. However, the amount ofthe organic catalyst is preferably 0.01 mol % to 15 mol %, morepreferably 0.1 mol % to 1 mol %, still more preferably 0.3 mol % to 0.5mol %, relative to 100 mol % of the ring-opening polymerizable monomer.When the amount of the organic catalyst used is less than 0.01 mol %,the organic catalyst is deactivated before completion of thepolymerization reaction, and as a result a polymer having a targetmolecular weight cannot be obtained in some cases. Whereas when theamount of the organic catalyst used is more than 15 mol %, it may bedifficult to control the polymerization reaction.

Also, the polymerization reaction temperature cannot flatly bedetermined since it varies depending on, for example, combinations ofthe compressive fluid, the ring-opening polymerizable monomer and theorganic catalyst. In general, the polymerization reaction temperature ispreferably 40° C. to 150° C., more preferably 50° C. to 120° C., stillmore preferably 60° C. to 100° C. When the polymerization reactiontemperature is lower than 40° C., the reaction rate easily decreases,and as a result the polymerization reaction cannot be made to proceedquantitatively in some cases. Whereas when the polymerization reactiontemperature exceeds 150° C., depolymerization reaction proceeds inparallel, and as a result the polymerization reaction cannot be made toproceed quantitatively in some cases.

The polymerization reaction time is appropriately determined consideringthe target number average molecular weight of the polymer. When thenumber average molecular weight is in the range of 3,000 to 100,000, thepolymerization reaction time is generally 2 hours to 12 hours.

Also, in order for the polymerization reaction to proceed uniformly andquantitatively, the difference in density between the monomers and thepolymer particles is compensated through stirring so that the polymerparticles do not sediment.

The pressure upon polymerization; i.e., the pressure of the compressivefluid, is preferably a pressure at which the compressive fluid isbrought into a supercritical state in order to increase dissovability ofthe monomer into the compressive fluid and make the polymerizationreaction to proceed uniformly and quantitatively, although thecompressive fluid may be high-pressure gas or liquefied gas. When carbondioxide is used as the compressive fluid, the pressure is preferably 3.7MPa or higher, more preferably 7.4 MPa or higher.

Upon polymerization, a ring-opening polymerization initiator ispreferably added to the reaction system in order to control themolecular weight of the obtained polymer. The ring-openingpolymerization initiator is not particularly limited and may be thoseknown in the art such as alcohols. The alcohols may be, for example, anyof saturated or unsaturated, aliphatic mono-, di- or polyalcohols.Specific examples thereof include monoalcohols such as methanol,ethanol, propanol, butanol, pentanol, hexanol, heptanol, nonanol,decanol, lauryl alcohol, myristyl alcohol, cetyl alcohol and stearylalcohol; dialcohols such as ethylene glycol, 1,2-propanediol,1,3-propanediol, 1,3-butanediol, 1,4-butanediol, hexanediol, nonanediol,tetramethylene glycol and polyethylene glycol; polyalcohols such asglycerol, sorbitol, xylitol, ribitol, erythritol and triethanolamine;and methyl lactate and ethyl lactate. Also, use of a polymer containingan alcohol residue at the end enables synthesis of diblock copolymersand triblock compolymers.

The amount of the ring-opening polymerization initiator used may beappropriately adjusted considering the target molecular weight of thepolymer. Preferably, the amount of the ring-opening polymerizationinitiator is about 0.1 parts by mass to about 5 parts by mass relativeto 100 parts by mass of the ring-opening polymerizable monomer.

If necessary, a polymerization terminator (e.g., benzoic acid,hydrochloric acid, phosphoric acid, metaphosphoric acid, acetic acid andlactic acid) may be used after completion of polymerization reaction.

In the present invention, the polymerization system contains asurfactant that dissolves in the compressive fluid and has compatibilityto both the compressive fluid and the ring-opening polymerizablemonomer. For example, when supercritical carbon dioxide is used as thecompressive fluid, the surfactant having a CO₂-philic group and amonomer-philic group in the molecule is used. Examples of the CO₂-philicgroup include a perfluoroalkyl group, a polydimethylsiloxane group, anether group and a carbonyl group. The monomer-philic group may beselected in consideration of the type of the monomer used. For example,when the monomer used is a lactide or lactone, preferred are surfactantshaving a carbonyl group in the form of, for example, an ester bond andan amide bond.

When the surfactant is incorporated into the polymerization system, thesurfactant may be added to the compressive fluid or the ring-openingpolymerizable monomer.

Specific examples of the surfactant include those containing, as apartial structure, a structure represented by any one of GeneralFormulas (1a) to (7a):

where R1 to R5 each represent a hydrogen atom or a C1-C4 lower alkylgroup, R6 to R8 represent a C1-C4 lower alkyl group, and each of m, nand k is an integer indicating the number of repeating units wherem/n=0.3 to 70 and 1≦k≦4; and also, the number average molecular weightof the surfactant is 7,000 or lower,

where R9 represents a hydrogen atom or a methyl group, R10 represents amethylene group or an ethylene group, Rf represents a C7-C10perfluoroalkyl group and q is an integer indicating the number ofrepeating units; and also, the number average molecular weight of thesurfactant is 2,500 or lower,

where R9 represents a hydrogen atom or a methyl group and each of r andp is an integer indicating the number of repeating units; and also, thenumber average molecular weight of the surfactant is 5,500 or lower,

where R6 to R8 each represent a C1-C4 lower alkyl group, R represents aC1-C4 lower alkylene group, and each of m, n and p is an integerindicating the number of repeating units where m/n=0.3 to 70; and also,the number average molecular weight of the surfactant is 5,000 or lower,

where n is an integer indicating the number of repeating units and Medenotes a methyl group; and the number average molecular weight of thesurfactant is 5,000 or lower,

where R9 represents a C1-C4 lower alkyl group, X represents ahydrophilic group (e.g., a hydroxy group, a carboxyl group and an aminogroup), each of m and n is an integer indicating the number of repeatingunits where m/n=0.3 to 70 and Me denotes a methyl group; and the numberaverage molecular weight of the surfactant is 5,000 or lower,

where R10 represents a C1-C4 lower alkyl group, Y represents an oxygenatom or a sulfur atom, each of m and n is an integer indicating thenumber of repeating units where m/n=0.3 to 70, Me denotes a methyl groupand Ph denotes a phenyl group; and the number average molecular weightof the surfactant is 5,000 or lower.

Among others, preferred are the surfactants containing a partialstructure represented by General Formula (1a), in which R6 to R8 eachpreferably represent a methyl group and k is preferably 2. When k issmall, the pyrrolidone skeleton and the silicone skeleton become closertogether sterically, and the surfactant having such a structure degradesin its actions as a surfactant. When k becomes greater, thedissolvability in the compressive fluid may be decreased.

The surfactant containing the partial structure represented by GeneralFormula (1a) is particularly preferably surfactant 1 given below. Thissurfactant is commercially available from Croda Japan under the tradename of “MONASIL PCA.”

Surfactant 1

where Me denotes a methyl group.

The surfactant used in the present invention may be other surfactantsthan those represented by General Formulas (1a) to (7a), so long as theydissolve in the compressive fluid and have compatibility to both thecompressive fluid and the ring-opening polymerizable monomer. Examplesof the other surfactants include those represented by the followingGeneral Formulas (8a) to (11a), where each of m and n is an integerindicating the number of repeating units.

The surfactant to be used is appropriately selected depending on thetype of the compressive fluid or considering whether the target productis polymer particles and seed particles (described below) or growthparticles. From the viewpoint of sterically and electrostaticallypreventing the resultant polymer particles from being aggregated,particularly preferred are surfactants that have high compatibility andadsorbability to the surfaces of the polymer particles and also havehigh compatibility and dissolvability to the compressive fluid. Of thesesurfactants, particularly preferred are those having a block structureof hydrophilic groups and hydrophobic groups, since they have anexcellent granularity.

Also, in order to increase steric repulsion between the particles, thesurfactants selected have a molecular chain of a certain length,preferably have a number average molecular weight of 10,000 or higher.However, when the molecular weight is too large, the surfactant isconsiderably increased in liquid viscosity, causing poor operability andpoor stirring performance. As a result, a large amount of the surfactantmay be deposited on the surfaces of some particles while a small amountof the surfactant may be deposited on the surfaces of other particles.Thus, care should be taken about selection of the surfactant.

The amount of the surfactant used varies depending on the type of thering-opening polymerizable monomer or the surfactant. In general, it ispreferably 0.1% by mass to 10% by mass, more preferably 1% by mass to 5%by mass, relative to the amount of the compressive fluid.

When the concentration of the surfactant in the compressive fluid islow, the produced polymer particles have a relatively large particlediameter. When the concentration of the surfactant in the compressivefluid is high, the produced polymer particles have a small particlediameter. However, even when used in an amount exceeding 10% by mass,the surfactant does not contribute to the production of the polymerparticles having a small particle diameter.

The particles produced at an early stage of polymerization arestabilized by the surfactant existing in equilibrium between thecompressive fluid and the surfaces of the polymer particles. However,when the ring-opening polymerizable monomer is contained in thecompressive fluid in a considerably large amount, the concentration ofthe polymer particles becomes high, resulting in that the polymerparticles disadvantageously aggregate regardless of steric repulsioncaused by the surfactant.

Further, when the amount of the ring-opening polymerizable monomer isextremely larger than that of the compressive fluid, the producedpolymer is totally dissolved, resulting in that the polymer isprecipitated only after the polymerization proceeds to some extent. Inthis case, the precipitated polymer particles are in the form of highlyadhesive aggregated matter.

For this reason, limitation is imposed on the amount of the ring-openingpolymerizable monomer used for producing polymer particles relative tothe compressive fluid. The amount thereof is preferably 500 parts bymass or less, more preferably 250 parts by mass or less, relative to 100parts by mass of the compressive fluid. However, since the density ofthe ring-opening polymerizable monomer varies depending on the state ofthe compressive fluid, the amount of the ring-opening polymerizablemonomer also varies depending on the state of the compressive fluid.

The production method according to a first embodiment of the presentinvention can produce polymer particles having an average particlediameter of submicron to 1 mm. The particle diameter can be controlledby controlling, for example, the pressure, temperature and reaction timeduring the reaction, and the amount of the surfactant used. Ifnecessary, by varying the reaction conditions, various polymer particlesfrom truly spherical polymer particles to amorphous polymer particlescan be obtained.

The polymerization method employable in the present invention is, forexample, dispersion polymerization, suspension polymerization andemulsion polymerization, and may be selected from these methodsdepending on the intended purpose. In particular, dispersionpolymerization is superior to suspension polymerization or emulsionpolymerization, since it can make the most of the advantages of thecompressive fluid, monodispersed polymer particles can be obtained, andthe produced polymer particles have a narrow particle size distribution.

In an another employable method, polymer particles (seed particles),having a smaller particle diameter than the target particle diameter anda narrow particle size distribution, are added in advance and grownthrough reaction with the monomer in the same system as described above.

The monomer used in the growth reaction may be the same as or differentfrom that used for producing the seed particles. The produced polymermust be dissolved in the compressive fluid.

By returning the compressive fluid in which the polymer produced in theabove-described method has been dispersed to the normal temperature andnormal pressure, dried polymer particles can be obtained.

In a first embodiment of the present invention, a polymerizationinitiator may be employed. Examples of the polymerization initiatorinclude aliphatic monoalcohols and polyalcohols.

Examples of the aliphatic monoalcohol include methanol, ethanol,propanol, isopropanol, butanol, hexanol and pentanol.

Examples of the aliphatic polyalcohol include ethylene glycol, propyleneglycol, 1,3-butanediol, 1,4-butanediol, 2,3-butanediol, diethyleneglycol, triethylene glycol, 1,5-pentanediol, 1,6-hexanediol, neopentylglycol, 2-ethyl-1,3-hexanediol, polyethylene glycol, triethanol amine,hydrogenated bisphenol A, and divalent alcohols obtained by adding tobisphenol A a cyclic ether such as ethylene oxide or propylene oxide.

One exemplary process of the polymerization is as follows. Specifically,a surfactant is completely dissolved in a compressive fluid; one or morering-opening polymerizable monomers and a polymerization initiator areadded to the compressive fluid; and the resultant mixture is heated to atemperature corresponding to the decomposition rate of thepolymerization initiator while stirred at a rate at which the flow ofthe reaction container becomes uniform. In general, the heatingtemperature is preferably 40° C. to 100° C., more preferably 50° C. to85° C.

Notably, the temperature at an early stage of the polymerization greatlyinfluences the particle diameter of the produced polymer particles.Thus, in a more preferable manner, after addition of the ring-openingpolymerizable monomer, the temperature of the resultant mixture isincreased to the polymerization temperature, and then the polymerizationinitiator is dissolved in a small amount of the compressive fluid andadded to the mixture.

Upon polymerization, the reaction container must be purged with an inertgas (e.g., nitrogen gas, argon gas or carbon dioxide gas) tosufficiently remove water contained in the air of the reactioncontainer. When water is not removed sufficiently, the particle diameterof the produced polymer particles cannot be made to be uniform,resulting in that fine particles are easily formed.

In order to increase the polymerization rate, the polymerization must beperformed for 5 hours to 72 hours. The polymerization speed can beincreased by terminating the polymerization when the desired particlediameter and particle size distribution are attained, by graduallyadding the polymerization initiator, or by performing the reaction underhigh-pressure conditions.

<Addition Polymerizable Monomer>

The addition polymerizable monomer may be appropriately selected inconsideration of the intended use of the obtained polymerized polymer.Examples thereof include addition polymerizable monomers having anunsaturated double bond such as vinyl monomers. Also, a wide variety ofaddition polymerizable monomers are commercially available.

Examples of the addition polymerizable monomer include styrene compoundssuch as styrene, o-methylstyrene, m-methylstyrene, p-methylstyrene,p-methoxystyrene and p-ethylstyrene; methyl acrylate, ethyl acrylate,propyl acrylate, n-butyl acrylate, isobutyl acrylate, n-octyl acrylate,dodecyl.acrylate, 2-ethylhexyl acrylate, stearyl acrylate, phenylacrylate, dimethylaminoethyl acrylate, diethylaminoethyl acrylate, andmethacrylates including methyl methacrylate, ethyl methacrylate, propylmethacrylate, n-butyl methacrylate, isobutyl methacrylate, n-octylmethacrylate, dodecyl methacrylate, 2-ethylhexyl methacrylate, stearylmethacrylate, phenyl methacrylate, dimethylaminoethy methacrylate anddiethylaminoethy methacrylate; acrylonitrile; methacrylonitrile; andacrylamide.

In the present invention, the polymerization system contains asurfactant that dissolves in the compressive fluid and has compatibilityto both the compressive fluid and the addition polymerizable monomer.For example, when supercritical carbon dioxide is used as thecompressive fluid, the surfactant having a CO₂-philic group (a grouphaving compatibility to carbon dioxide) and a monomer-philic group (agroup having compatibility to monomer) in the molecule is used. Examplesof the CO₂-philic group include a perfluoroalkyl group, apolydimethylsiloxane group, an ether group and a carbonyl group. Themonomer-philic group is preferably a polymer chain formed of theaddition polymerizable monomers used.

When the surfactant is incorporated into the polymerization system, thesurfactant may be added to the compressive fluid or the polymerizablemonomer.

Examples of the surfactant include fluorine-containing surfactants andsilicone surfactants. In the present invention, the silicone surfactantis used. The silicone surfactant is preferably a silicone surfactantrepresented by the following General Formula (1), (2) or (3).

In General Formula (1), Me denotes a methyl group; one or two among R¹,R² and R³ each represent a residue containing a C6-C30 long-chain alkylgroup and the rest represents a residue containing a C1-C4 lower alkylgroup; and each of m and n is an integer of 1 or greater indicating thenumber of repeating units. In General Formula (2), R⁴ and R⁶ eachrepresent a hydrogen atom or a methyl group, R⁵ represents a methylenegroup or an ethylene group, and each of m and n is an integer of 1 orgreater indicating the number of repeating units. In General Formula(3), at least one of R⁷ and R⁸ represents a residue containing a C6-C30long-chain alkyl group and the other represents a residue containing aC1-C4 lower alkyl group; R⁹ to R¹³ each represent a hydrogen atom or aC1-C4 lower alkyl group; and each of m and n is an integer of 1 orgreater indicating the number of repeating units.

Here, the above long-chain alkyl group refers to alkyl groups having 6or more carbon atoms. The upper limit of the number of carbon atoms ofthe long-chain alkyl group is not particularly limited, but excessivelylong alkyl groups may have poor compatibility to the compressive fluid.Thus, the number of carbon atoms of the long-chain alkyl group ispreferably 6 to 30, more preferably 8 to 28.

Examples of the C1-C4 lower alkyl group include a methyl group, an ethylgroup, various propyl groups and various butyl groups. Examples of theC6-C30 long-chain alkyl group include various hexyl groups, variousheptyl groups, various octyl groups, various nonyl groups, various decylgroups, various undecyl groups, various dodecyl groups, various tridecylgroups, various tetradecyl groups, various pentadecyl groups, varioushexadecyl groups, various heptadecyl groups, various octadecyl groupsand various icosyl groups.

“m” is generally about 1 to about 70, preferably 10 to 40. “n” isgenerally about 1 to about 30, preferably 10 to 20.

Specific examples of the surfactants represented by General Formula (1)include the following.

where Me denotes a methyl group, R²¹ to R²⁶ each represent an alkylgroup and k is 4, 16 or 28; and each of m and n is an integer indicatingthe number of repeating units.

Specific examples of the surfactants represented by General Formula (2)include the following.

where Me denotes a methyl group and R²⁷ represents a methylene group oran ethylene group; and each of m and n is an integer indicating thenumber of repeating units.

Specific examples of the surfactants represented by General Formula (3)include the following. Notably this compound is commercially availablefrom Croda Co. under the product name of “MONASIL PCA.”

where Me denotes a methyl group; and each of m and n is an integerindicating the number of repeating units.

The silicone surfactants can be obtained with a common synthesis method.For example, silicone oil serving as a raw material is changed inmolecular weight and viscosity through amidation or esterification usingreactive silicone oil whose end or side chain has been modified, wherebysurfactants having various properties can be obtained.

Examples of the reactive silicone oil include silicon oils diol-modifiedat a single end, those carbinol-modified at a single end, thosecarboxyl-modified at a single end, those carbinol-modified at a sidechain, those amino-modified at a side chain, those amino-modified at aside chain and methoxy-modified at both ends, those carboxyl-modified ata side chain, those carbinol-modified at both ends, those amino-modifiedat both ends, those silanol-modified at both ends and thosecarboxyl-modified at both ends.

The silicone surfactant to be used is appropriately selected dependingon the type of the compressive fluid or considering whether the targetproduct is polymer particles or seed particles (described below). Fromthe viewpoint of sterically preventing the resultant polymer particlesfrom being aggregated, particularly preferred are silicone surfactantsthat have high compatibility and adsorbability to the surfaces of thepolymer particles and also have high compatibility and dissolvability tothe compressive fluid.

Also, in order to increase steric repulsion between the particles, thesilicone surfactants selected have a molecular chain of a certainlength, preferably have a number average molecular weight of 10,000 orhigher.

However, when the number average molecular weight is too large, thesilicone surfactant is considerably increased in liquid viscosity,causing poor operability and poor stirring performance. As a result, alarge amount of the silicone surfactant may be deposited on the surfacesof some particles while a small amount of the silicone surfactant may bedeposited on the surfaces of other particles. Thus, care should be takenabout selection of the silicone surfactant.

The amount of the silicone surfactant used varies depending on the typeof the addition polymerizable monomer or the surfactant. In general, itis preferably 0.1 parts by mass to 10 parts by mass, more preferably 1part by mass to 5 parts by mass, relative to 100 parts by mass of thecompressive fluid.

When the concentration of the surfactant in the compressive fluid islow, the produced polymer particles have a relatively large particlediameter. When the concentration of the surfactant in the compressivefluid is high, the produced polymer particles have a small particlediameter. However, even when used in an amount exceeding 10% by mass,the surfactant does not contribute to the production of the polymerparticles having a small particle diameter.

Also, use of fine powder of an inorganic compound in combination withthe silicone surfactant further promotes stabilization of the producedpolymer particles and improvement of the particle size distribution.

The particles produced at an early stage of polymerization arestabilized by the surfactant existing in equilibrium between thecompressive fluid and the surfaces of the polymer particles. However,when unreacted addition polymerizable monomers are contained in thecompressive fluid in a considerably large amount, the concentration ofthe polymer particles becomes high, resulting in that the polymerparticles disadvantageously aggregate regardless of steric repulsioncaused by the surfactant.

Further, when the amount of the addition polymerizable monomer isextremely larger than that of the compressive fluid, the producedpolymer is disadvantageously dissolved in the monomer, resulting in thatthe polymer is precipitated only after the polymerization proceeds tosome extent. In this case, the precipitated polymer particles are in theform of aggregated matter rather than particles.

For this reason, limitation is imposed on the amount of the additionpolymerizable monomer used for producing polymer particles relative tothe compressive fluid. The amount thereof is preferably 500 parts bymass or less, more preferably 250 parts by mass or less, relative to 100parts by mass of the compressive fluid. However, since the density ofthe addition polymerizable monomer varies depending on the state of thecompressive fluid, the amount of the addition polymerizable monomer alsovaries depending on the state of the compressive fluid.

In a second embodiment of the present invention, the additionpolymerizable monomer is polymerized to obtain polymer particles.Regarding the polymerization method, dispersion polymerization issuperior to suspension polymerization or emulsion polymerization, sinceit can make the most of the advantages of the compressive fluid,monodispersed polymer particles can be obtained, and the producedpolymer particles have a narrow particle size distribution.

In an another employable method, polymer particles (seed particles),having a smaller particle diameter than the target particle diameter anda narrow particle size distribution, are added in advance and grownthrough reaction with the monomer in the same system as described above.

The monomer used in the growth reaction may be the same as or differentfrom that used for producing the seed particles. The produced polymermust be dissolved in the compressive fluid.

By returning the compressive fluid in which the polymer produced in theabove-described method has been dispersed to the normal temperature andnormal pressure (25° C., 0.1 MPa), dried polymer particles can beobtained.

In a second embodiment of the present invention, a polymerizationinitiator may be used for polymerizing the addition polymerizablemonomer. The polymerization initiator may be commonly used radicalinitiators.

Examples of the radical initiator include azo polymerization initiatorssuch as 2,2′-azobisisobutylonitrile (AIBN),azobis(2,4-dimethylvaleronitrile) and1,1′-azobis(cyclohexane-1-carbonitrile); and peroxide initiators such aslauryl peroxide, benzoyl peroxide, tert-butyl peroctoate, methyl ethylketone peroxide, isopropyl peroxycarbonate, cumene hydroperoxide,2,4-dichlorobenzoyl peroxide and potassium persulfate. In addition,there are used systems in which the above peroxide initiator is used incombination with sodium thiosulfate, amine, etc.

The amount of the polymerization initiator used is preferably 0.1 partsby mass to 10 parts by mass relative to 100 parts by mass of theaddition polymerizable monomer.

One exemplary process of the polymerization is as follows. Specifically,a silicone surfactant is completely dissolved in a compressive fluid;one or more addition polymerizable monomers and a polymerizationinitiator are added to the compressive fluid; and the resultant mixtureis heated to a temperature corresponding to the decomposition rate ofthe polymerization initiator while stirred at a rate at which the flowof the reaction container becomes uniform. In general, the heatingtemperature is preferably 40° C. to 100° C., more preferably 50° C. to85° C.

Notably, the temperature at an early stage of the polymerization greatlyinfluences the particle diameter of the produced polymer particles.Thus, in a more preferable manner, after addition of the additionpolymerizable monomer, the temperature of the resultant mixture isincreased to the polymerization temperature, and then the initiator isdissolved in a small amount of the compressive fluid and added to themixture.

Upon polymerization, the reaction container must be purged with an inertgas (e.g., nitrogen gas, argon gas or carbon dioxide gas) tosufficiently remove oxygen contained in the air of the reactioncontainer. When oxygen is not purged sufficiently, fine particles areeasily formed.

In order to increase the polymerization rate, the polymerization must beperformed for 5 hours to 72 hours. The polymerization speed can beincreased by terminating the polymerization when the desired particlediameter and particle size distribution are attained, by graduallyadding the polymerization initiator, or by performing the reaction underhigh-pressure conditions.

Also, in polymerizing the addition polymerizable monomer, a compoundhaving a high chain transfer constant may be used together to controlthe average molecular weight.

Examples of the compound having a high chain transfer constant includelow-molecular-weight compounds having a mercapto group, carbontetrachloride and carbon tetrabromide. Examples of other compoundspreferably used include halogenated hycrocarbons such as ethyl acetatedibromide, ethyl acetate tribromide, ethyl benzene dibromide, ethanebromide and ethane dichloride; hydrocarbons such as diazothio ether,benzene, ethylbenzene and isopropylbenzene; mercaptans such astert-dodecyl mercaptan and n-dodecyl mercaptan; disulfides such asdiisopropylxanthogen disulfide; thioglycolic acid derivatives such asthioglycolic acid, 2-ethylhexyl thioglycolate, butyl thioglycolate,methoxybutyl thioglycolate, trimethylolpropane tris(thioglycolate) andammonium thioglycolate; and thioglycerol.

The amount of the chain transfer agent used may be 10⁻³ parts by mass to10 parts by mass relative to 100 parts by mass of the additionpolymerizable monomer.

When the chain transfer agent is added before initiation ofpolymerization, the molecular weight of the polymer produced at an earlystage can be adjusted to control the size of the precipitated nuclearparticles.

When the chain transfer agent is added after precipitation of nuclearparticles, the molecular weight of the produced polymer particles can beadjusted to obtain flowability when the polymer particles are meltedthrough application of heat of a desired amount.

The polymer particles of the present invention produced in this mannerhave a molecular weight distribution (Mw/Mn: Mw denotes a weight averagemolecular weight and Mn denotes a number average molecular weight) of2.0 or lower.

EXAMPLES

The present invention will next be described in more detail by way ofExamples and Comparative Examples, which should not be construed aslimiting the present invention thereto.

Notably, regarding the polymers produced in Examples and ComparativeExamples, the number average molecular weight and the conversion rate ofmonomer to polymer were measured as follows.

<Measurement of Number Average Molecular Weight of Polymer>

The number average molecular weight was measured through gel permeationchromatography or GPC under the following conditions.

Apparatus: GPC-8020 (product of TOSOH CORPORATION)Column: TSK G2000HXL and G4000HXL (product of TOSOH CORPORATION)

Temperature: 40° C. Solvent: Tetrahydrofuran or THF

Flow rate: 1.0 mL/min

First, a calibration curve of molecular weight was obtained usingmonodispersed polystyrene serving as a standard sample. A polymer sample(1 mL) having a polymer concentration of 0.5% by mass was applied andmeasured under the above conditions, to thereby obtain the molecularweight distribution of the polymer. The number average molecular weightMn and the weight average molecular weight Mw of the polymer werecalculated from the calibration curve. The molecular weight distributionis a value calculated by dividing Mw with Mn.

<Electron Microscopic Observation of Polymer>

The polymer was observed with a scanning electron microscope or SEMunder the following conditions.

Apparatus: JSM-5600 (product of JEOL Ltd.)Secondary electron image resolution: 3.5 nmMagnification: ×18 to ×300,000 (136 steps in total)Applied current: 10⁻¹² A to 10⁻⁸ AAcceleration voltage: 0.5 kV to 30 kV (53 steps)Sample holder: 10 mm (diameter)×10 mmh sample holder

-   -   32 mm (diameter)×10 mmh sample holder        Maximum size of sample: 15.24 cm (6 inch) (diameter)        Pixel count: 640×480, 1,280×960

<Conversion Rate of Monomer to Polymer (mol %)=100−Amount of UnreactedMonomer (mol %)>

In the case of polylactic acid, the amount of unreacted monomer (mol %)was calculated in deuterated chloroform with a nuclear magneticresonance apparatus JNM-AL300 (product of JEOL Ltd.) as a value obtainedas follows: 100×the ratio of a quartet peak area attributed to lactide(4.98 ppm to 5.05 ppm) to a quartet peak area attributed to polylacticacid (5.10 ppm to 5.20 ppm).

In the case of polycaprolactone, the amount of unreacted monomer (mol %)was calculated in deuterated chloroform with a nuclear magneticresonance apparatus JNM-AL300 (product of JEOL Ltd.) as a value obtainedas follows: 100×the ratio of a triplet peak area attributed tocaprolactone (4.22 ppm to 4.25 ppm) to a triplet peak area attributed topolycaprolactone (4.04 ppm to 4.08 ppm).

In the case of polycarbonate, the amount of unreacted monomer (mol %)was calculated in deuterated chloroform with a nuclear magneticresonance apparatus JNM-AL300 (product of JEOL Ltd.) as a value obtainedas follows: 100×the ratio of a singlet peak area attributed to ethylenecarbonate (4.54 ppm) to a quartet peak area attributed to polycarbonate(4.22 ppm to 4.25 ppm).

Synthesis Example A1 Synthesis of Surfactant A2

1H, 1H-Perfluorooctyl acrylate (product of AZmax. co) (1,250 parts bymass) and 2,2′-azobis(2,4-dimethylvaleronitrile) (product of Wako PureChemical Industries, Ltd., V-65) (62.5 parts by mass) were charged intoa pressure-resistant cell (in an amount of 50% by volume of thepressure-resistant cell). Carbon dioxide was selected as a supercriticalfluid and supplied into the above reaction cell with a supply bomb. Thereaction was performed for 24 hours while the pressure and thetemperature were being adjusted to 15 MPa and 85° C. with a pressurepump and a temperature controller.

Next, the temperature was decreased to 0° C., and the pressure wasdecreased to normal pressure using a back pressure valve, to therebyobtain surfactant A2 having the following Structural Formula. The numberaverage molecular weight (Mn) thereof was found to be 2,500.

Surfactant A2

Synthesis Example A2 Synthesis of Surfactant A3

Polyacrylic acid 5,000 (product of Wako Pure Chemical Industries, Ltd.)(36.1 parts by mass), chloroform (product of Wako Pure ChemicalIndustries, Ltd.) (1,480 parts by mass) and1,1′-carbonylbis-1H-imidazole (128 parts by mass) were added to a 6mL-vial container, followed by stirring at room temperature for 10 min.

Next, polyethylene glycol (product of Wako Pure Chemical Industries,Ltd., molecular weight: 200) (500 parts by mass) was added thereto,followed by stirring at room temperature for 12 hours.

Next, chloroform was added thereto, followed by washing with water.

Next, the resultant reaction mixture was dried with sodium sulfateanhydrate, filtrated and concentrated under reduced pressure, to therebyobtain surfactant A3 having the following Structural Formula (yield: 73%by mass). The number average molecular weight thereof was found to be5,200.

Surfactant A3

Synthesis Example A3 Synthesis of Surfactant A4

Silicone oil carboxy-modified at its side chain (product of Shin-EtsuSilicones Co., KF-8012, number average molecular weight: 4,500) (12parts by mass), chloroform (product of Wako Pure Chemical Industries,Ltd.) (33.3 parts by mass), 1,1′-carbonylbis-1H-imidazole (product ofWako Pure Chemical Industries, Ltd., molecular weight: 200) (0.65 partsby mass) and polyethylene glycol (product of Wako Pure ChemicalIndustries, Ltd., molecular weight: 200) (0.80 parts by mass) were addedto a 50 mL-egg plant flask, followed by stirring at room temperature for12 hours.

Next, a saturated sodium hydrogen carbonate aqueous solution was addedthereto and the sodium stearate that precipitated was filtered off witha kiriyama funnel, followed by washing with a saturated sodium hydrogencarbonate aqueous solution.

Next, the resultant reaction mixture was dried with sodium sulfateanhydrate, filtrated with silica gel and concentrated under reducedpressure, to thereby obtain surfactant A4 having the followingStructural Formula (yield: 91% by mass). The number average molecularweight thereof was found to be 4,700.

Surfactant A4

Synthesis Example A4 Synthesis of Surfactant A9

Silicone oil amino-modified at its side chain and methoxy-modified atboth ends (product of Shin-Etsu Silicones Co., KF-857, molecular weight:790) (7.9 parts by mass), dichloromethane (product of Tokyo ChemicalIndustry Co., Ltd.) (66.6 parts by mass) and phenyl isocyanate (productof KANTO KAGAKU) (3.6 parts by mass) were added to a 300 mL-egg plantflask, followed by stirring at room temperature for 24 hours.Thereafter, hexane was added thereto, followed by washing with distilledwater. The resultant reaction mixture was dried with sodium sulfateanhydrate and filtrated with cotton and silica gel, and the solvent wasevaporated under reduced pressure, to thereby obtain surfactant A9having the following Structural Formula (yield: 80%).

Synthesis Example A5 Synthesis of Surfactant A10

The procedure of Synthesis Example A4 was repeated, except that phenylisocyanate was changed to phenyl isothiocyanate (product of Wako PureChemical Industries, Ltd.) (4.0 parts by mass), to thereby obtainsurfactant A10.

Example A1

A micro tube was charged with L-lactide (882.4 parts by mass),4-dimethylaminopyridine (48.9 parts by mass), surfactant A1 (49.7 partsby mass) and anhydrous ethanol (9.2 parts by mass). The micro tube wasplaced in a pressure-resistant container and heated to 60° C. Then,supercritical carbon dioxide (60° C., 10 MPa) was charged thereinto,followed by reaction at 60° C. for 2 hours.

Next, the pressure pump and the back pressure valve were used to adjustthe flow rate at the outlet of the back pressure valve to 5.0 L/min.Then, supercritical carbon dioxide was allowed to flow for 30 min. Afterthe organic catalyst and the residual monomers had been removed, thereaction system was gradually returned to normal temperature and normalpressure. Three hours after, polymer particles A1 contained in thecontainer were taken out.

FIG. 3 is an electron microscope image showing the aggregation state ofpolymer particles A1. FIG. 4 is an electron microscope image of each ofpolymer particles A1. FIG. 5 is an image obtained by photographingpolymer particle A1 with a digital camera. As is clear from theseimages, the produced polymer particles were found to have a size ofabout 40 μm or less.

Also, with the above method, polymer particles A1 were measured forphysical properties (Mn, Mw/Mn, polymer conversion rate), which areshown in Table A1.

Examples A2 to A24

The procedure of Example A1 was repeated, except that the catalyst used,the type and amount of the surfactant, the type of the monomer and thereaction conditions are changed as shown in the respective columns ofExamples A2 to A24 in Tables A1 and A2, to thereby obtain polymerparticles A2 to A24. Notably, surfactants A5 to A8 have structuresexpressed by the following General Formulas.

Surfactant A5

-   -   X-22-162C: product of Shin-Etsu Silicones Co.

Surfactant A6

-   -   PAM-E: product of Shin-Etsu Silicones Co.

Surfactant A7

-   -   X-22-3701E: product of Shin-Etsu Silicones Co.

Surfactant A8

-   -   KF-868: product of Shin-Etsu Silicones Co.

From electron photographic images of the polymer particles photographedin the same manner as in Example A1, the polymer particles were found tobe somewhat varied in size but have a similar size to those of ExampleA1.

Also, with the above method, these polymer particles were measured forphysical properties (Mn, Mw/Mn, polymer conversion rate), which areshown in Tables A1 and A2.

Comparative Examples A1 and A2

The procedure of Example A1 was repeated, except that no surfactant wasused, and the type and amount of the monomer were changed as shown inthe columns of Comparative Examples A1 and A2 in Table A2 for producingpolymer particles. As a result, only aggregated polymer could beobtained.

With the above method, the aggregated polymer was measured for physicalproperties (Mn, Mw/Mn, polymer conversion rate), which are shown inTable A2. Also, FIG. 6 is a photograph of the aggregated polymer ofComparative Example A1, which was taken with a digital camera.

TABLE A1 Ex. A1 Ex. A2 Ex. A3 Ex. A4 Ex. A5 Ex. A6 Ex. A7 Ex. A8 Ex. A9Ex. A10 Ex. A11 Ex. A12 Catalyst DMAP DMAP DMAP DMAP DMAP DMAP DMAP DMAPDMAP DMAP DMAP DMAP Surfactant 1 1 1 1 1 1 1 1 1 1 1 1 Amount of 50 5050 50 50 50 50 50 50 50 50 50 surfactant (parts by mass) Type of L-L-lactide L-lactide L-lactide L- L- L- L- L- L- L- L- monomer lactide(80 mol %) (80 mol %) (80 mol %) lactide lactide lactide lactide lactidelactide lactide lactide δ-valero- ε-capro- cyclic lactone lactonecarbonate (20 mol %) (20 mol %) (20 mol %) Pressure 8 8 8 8 8 8 8 8 4 510 16 (MPa) Temperature 60 60 60 60 25 35 80 100 80 60 60 60 (° C.)Number 12000 18000 20000 18000 8500 7700 11000 14000 7700 10000 1100013000 average molecular weight (Mn) Molecular 1.3 1.1 1.4 1.3 1.4 1.21.4 1.3 1.5 1.5 1.4 1.4 weight distribution (Mw/Mn) Monomer 96 97 98 9676 81 92 90 68 86 95 95 conversion rate (mol %)

TABLE A2 Comp. Comp. Ex. A13 Ex. A14 Ex. A15 Ex. A16 Ex. A17 Ex. A18 Ex.A19 Ex. A20 Ex. A21 Ex. A22 Ex. A23 Ex. A24 Ex. A1 Ex. A2 Catalyst DABCODBU PPY DMAP DMAP DMAP DMAP DMAP DMAP DMAP DMAP DMAP DMAP DMAP Surfac- 11 1 2 3 4 5 6 7 8 9 10 — — tant Amount 50 50 50 72 83 85 87 89 83 84 8585 — — of surfac- tant (parts by mass) Type of L- L- L- L- L- L- L- L-L- L- L- L- L- L- mono- lactide lactide lactide lactide lactide lactidelactide lactide lactide lactide lactide lactide lactide lactide mer (80mol %) ε-capro- lactone (20 mol %) Pressure 8 8 8 8 8 8 8 8 8 8 8 8 8 8(MPa) Tem- 60 60 60 60 60 60 60 60 60 60 60 60 60 60 per- ature (° C.)Number 12000 14000 13000 20000 19000 12000 13000 20000 19000 12000 1900012000 12000 13000 average molec- ular weight (Mn) Molec- 1.5 1.4 1.4 1.21.3 1.4 1.3 1.2 1.3 1.4 1.3 1.3 1.4 1.6 ular weight distri- bution (Mw/Mn) Mono- 94 94 91 88 90 95 91 88 90 95 90 95 92 91 mer conver- sionrate (mol %)

Synthesis Example B1 Synthesis of Surfactant B1

Silicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) (1.4 parts by mass), chloroform (product of Wako PureChemical Industries, Ltd.) (33.3 parts by mass), anhydrous pyridine(product of KANTO KAGAKU) (1.7 parts by mass) and stearoyl chloride(product of Aldrich) (1.4 parts by mass) were added to a 50 mL-egg plantflask, followed by stirring at room temperature for 12 hours, to therebyobtain a reaction mixture.

A saturated sodium hydrogen carbonate aqueous solution (5 mL) was addedthereto and the sodium stearate that precipitated was filtered off witha kiriyama funnel. Then, the reaction mixture was washed with asaturated sodium hydrogen carbonate aqueous solution (5 mL×4).Subsequently, the resultant reaction mixture was dried with sodiumsulfate anhydrate, filtrated with silica gel and concentrated underreduced pressure, to thereby obtain surfactant B1 having the followingStructural Formula (yield: 69%).

The analytical results of surfactant B1 are as follows.

mp: 47.0° C.-53.0° C.

¹H NMR (CDCl₃, 300 MHz, MS-231-re) δ=0.044 (br, —SiCH₃), 0.877 (t,J=6.15 Hz, 5.45H, —CH₃), 1.25 (br, —CH₂(CH₂)₁₄CH₃), 1.56-1.65 (m,—CH₂(CH₂)₁₄CH₃)

IR (KBr, cm⁻¹, MS-258) 3301.9 (NH stretching vibration), 2954.7, 2918.1,2850.6 (s, CH₂ group C—H stretching vibration), 1645.2 (C=0 stretchingvibration)

Surfactant B1

where R²¹ represents an alkyl group, and each of m and n is an integerindicating the number of repeating units.

Synthesis Example B2 Synthesis of surfactant B2

The procedure of Synthesis Example B1 was repeated, except that thesilicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) was changed to silicone oil carbinol-modified at its sidechain (product of Shin-Etsu Silicones Co., X-22-4039), to thereby obtainsurfactant B2 (yield: 100%).

Surfactant B2

where R²² represents an alkyl group, and each of m and n is an integerindicating the number of repeating units.

Synthesis Example B3 Synthesis of Surfactant B3

The procedure of Synthesis Example B1 was repeated, except that thesilicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) was changed to silicone oil amino-modified at its side chain(product of Shin-Etsu Silicones Co., KF-868), to thereby obtainsurfactant B3 (yield: 100%).

Surfactant B3

where R²³ represents an alkyl group, and each of m and n is an integerindicating the number of repeating units.

Synthesis Example B4 Synthesis of Surfactant B4

The procedure of Synthesis Example B1 was repeated, except that thesilicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) was changed to silicone oil diol-modified at a single end(product of Shin-Etsu Silicones Co., X-22-176DX), to thereby obtainsurfactant B4 (yield: 100%).

Surfactant B4

where R²⁴ to R²⁶ each represent an alkyl group, and each of m and n isan integer indicating the number of repeating units.

Synthesis Example B5 Synthesis of Surfactant B5

The procedure of Synthesis Example B1 was repeated, except that thesilicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) was changed to silicone oil carbinol-modified at a singleend (product of Shin-Etsu Silicones Co., X-22-170BX) and that thestealoyl chloride was changed to polyacrylic acid (product of Wako PureChemical Industries, Ltd., number average molecular weight: 5,000), tothereby obtain surfactant B5 (yield: 90%).

Surfactant B5

where R²⁷ is a methylene group or an ethylene group, and each of m and nis an integer indicating the number of repeating units.

Synthesis Example B6 Synthesis of Surfactant B6

The procedure of Synthesis Example B1 was repeated, except that thesilicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) was changed to silicone oil carbinol-modified at its sidechain (product of Shin-Etsu Silicones Co., X-22-4039) and that thestealoyl chloride was changed to melissic chloride, to thereby obtainsurfactant B6 (yield: 93%).

Surfactant B6

where R²² represents an alkyl group, and each of m and n is an integerindicating the number of repeating units.

Synthesis Example B7 Synthesis of Surfactant B7

The procedure of Synthesis Example B1 was repeated, except that thesilicone oil amino-modified at both ends (product of Shin-Etsu SiliconesCo., PAM-E) was changed to silicone oil carbinol-modified at its sidechain (product of Shin-Etsu Silicones Co., X-22-4039) and that thestealoyl chloride was changed to caproic chloride, to thereby obtainsurfactant B7 (yield: 92%).

Surfactant B7

where R²² represents an alkyl group, and each of m and n is an integerindicating the number of repeating units.

Synthesis Example B8 Synthesis of Surfactant B9

1H, 1H-Perfluorooctyl acrylate (product of AZmax. co) (1,250 parts bymass) and 2,2′-azobis(2,4-dimethylvaleronitrile) (product of Wako PureChemical Industries, Ltd., V-65) (62.5 parts by mass) were charged intoa pressure-resistant cell (in an amount of 50% by volume of thepressure-resistant cell). Carbon dioxide was selected as a supercriticalfluid and supplied into the above reaction cell with a supply bomb. Thereaction was performed for 24 hours while the pressure and thetemperature were being adjusted to 15 MPa and 85° C. with a pressurepump and a temperature controller. Next, the temperature was decreasedto 0° C., and the pressure was decreased to normal pressure using a backpressure valve, to thereby obtain surfactant B9. The number averagemolecular weight (Mn) of surfactant B9 was found to be 2,500.

Surfactant B9

where n is an integer indicating the number of repeating units.

Example B1 (1) Preparation of Addition Polymerizable Monomer Composition

Styrene monomer (product of Wako Pure Chemical Industries, Ltd.) (20parts by mass) and surfactant B1 (5 parts by mass) were stirred togetherto prepare a homogeneous polymerizable monomer composition B1.

(2) Supercritical Polymerization Step

The above-prepared polymerizable monomer composition B1 (20 parts bymass) was charged into a pressure-resistant cell (in an amount of 20% byvolume of the pressure-resistant cell). Carbon dioxide was selected as asupercritical fluid and supplied into the above reaction cell with asupply bomb. The pressure and the temperature were adjusted to 30 MPaand 65° C. with a pressure pump and a temperature controller.

In addition, 2,2′-azobisisobutylonitrile (AIBN) (product of Wako PureChemical Industries, Ltd.) (1 part by mass) was added thereto as apolymerization initiator, followed by reaction for 40 hours.

After completion of reaction, the temperature was decreased to 5° C.while the pressure was being maintained. The pressure pump and the backpressure valve were used to adjust the flow rate at the outlet of theback pressure valve to 5.0 L/min. Then, supercritical carbon dioxide wasallowed to flow for 6 hours. After the residual monomers had beenremoved, the reaction system was gradually returned to normaltemperature and normal pressure, to thereby obtain polymer particles B1(yield: 31%). Polymer particles B1 were found to have a number averagemolecular weight (Mn) of 6,886 and a molecular weight distribution(Mw/Mn) of 1.96.

Examples B2 to B7

The procedure of Example B1 was repeated, except that surfactant B1 waschanged to surfactants B2 to B7 to prepare polymerizable monomercompositions B2 to B7, which were then subjected to the supercriticalpolymerization step, to thereby obtain polymer particles B2 to B7.

Example B8

The procedure of Example B1 was repeated, except that surfactant B1 waschanged to surfactant B8 having the following Structural Formula(product of Croda, “MONASIL PCA”) to prepare polymerizable monomercomposition B8, which was then subjected to the supercriticalpolymerization step, to thereby obtain polymer particles B8.

Comparative Example B1 (1) Preparation of Addition Polymerizable MonomerComposition

Styrene monomer (product of Wako Pure Chemical Industries, Ltd.) (20parts by mass) and surfactant B8 (5 parts by mass) were stirred togetherto prepare a homogeneous polymerizable monomer composition B9.

(2) Supercritical Polymerization Step

The above-prepared polymerizable monomer composition B9 (20 parts bymass) was charged into a pressure-resistant cell (in an amount of 20% byvolume of the pressure-resistant cell). Carbon dioxide was selected as asupercritical fluid and supplied into the above reaction cell with asupply bomb. The pressure and the temperature were adjusted to 30 MPaand 65° C. with a pressure pump and a temperature controller.

In addition, 2,2′-azobisisobutylonitrile (AIBN) (product of Wako PureChemical Industries, Ltd.) (1 part by mass) was added thereto as apolymerization initiator, followed by reaction for 40 hours.

After completion of reaction, the temperature was decreased to 5° C.while the pressure was being maintained. The pressure pump and the backpressure valve were used to adjust the flow rate at the outlet of theback pressure valve to 5.0 L/min. Then, supercritical carbon dioxide wasallowed to flow for 6 hours. After the residual monomers had beenremoved, the reaction system was gradually returned to normaltemperature and normal pressure, to thereby obtain polymer particles B9(yield: 31%). Polymer particles B9 were found to have a number averagemolecular weight (Mn) of 7,242 and a molecular weight distribution(Mw/Mn) of 7.10.

Comparative Example B2 (1) Preparation of Polymeriable MonomerComposition

Styrene monomer (product of Wako Pure Chemical Industries, Ltd.) waswashed with a 5% by mass aqueous sodium hydroxide solution, followed byevaporating under reduced pressure, to thereby obtain purified styrenemonomer containing no radical polymerization inhibitor.

The purified styrene monomer was bubbled with nitrogen gas for 15 minwhile being stirred with a stirrer, to thereby remove oxygen containedin the styrene monomer.

The thus-purified, deoxidized styrene monomer (1,900 parts by mass) wasadded to high-molecular-weight azo polymerization initiator (product ofWako Pure Chemical Industries, Ltd., VPS-1001) (13 parts by mass). Theresultant mixture was stirred with a stirrer at room temperature untilthe high-molecular-weight azo polymerization initiator (product of WakoPure Chemical Industries, Ltd., WS-1001) was dissolved completely, tothereby obtain a styrene solution of the high-molecular-weight azopolymerization initiator.

A high-pressure cell (volume: 10 mL) was blown with nitrogen gas toremove oxygen. The high-pressure cell was charged withazobisisobutylonitrile (product of Wako Pure Chemical Industries, Ltd.)(95 parts by mass) and the styrene solution of the high-molecular-weightazo polymerization initiator (product of Wako Pure Chemical Industries,Ltd., VPS-1001), followed by reaction, to thereby obtain polymerizablemonomer composition B10.

(2) Supercritical Polymerization Step

The above-prepared polymerizable monomer composition B10 (40 parts bymass) was charged into a pressure-resistant reaction cell (in an amountof 20% by volume of the pressure-resistant reaction cell). Carbondioxide was selected as a supercritical fluid and supplied into theabove reaction cell with a supply bomb. The pressure and the temperaturewere adjusted to 40 MPa and 65° C. with a pressure pump and atemperature controller. The reaction was performed for 24 hours toobtain polymer particles B10. After completion of reaction, thehigh-pressure cell was cooled to room temperature and returned to normalpressure while gradually discharging carbon dioxide, to thereby obtainpolymer particles B10 as white powder.

Polymer particles B10 were found to have a number average molecularweight (Mn) of 5,900 and a molecular weight distribution (Mw/Mn) of2.48.

The measurement results of the obtained polymer particles B10 are shownin Table B1.

TABLE B1 Comp. Comp. Ex. B1 Ex. B2 Ex. B3 Ex. B4 Ex. B5 Ex. B6 Ex. B7Ex. B8 Ex. B1 Ex. B2 Surfactant 1 2 3 4 5 6 7 8 9 — Number 6886 67737031 6418 6483 7211 6623 34185 7241 5900 average molecular weight (Mn)Molecular 1.96 1.79 1.82 1.79 1.81 1.85 1.76 1.45 7.10 2.48 weightdistribution (Mw/Mn)

The polymer particles of the present invention can be used for variousapplications such as electrophotographic developers, printing inks,building paints and cosmetics.

What is claimed is:
 1. A method for producing polymer particles,comprising: (A) polymerizing a ring-opening polymerizable monomer toproduce a polymer while granulating the polymer in a compressive fluidwith a catalyst in the presence of a surfactant, or (B) polymerizing anaddition polymerizable monomer to produce a polymer while granulatingthe polymer in a compressive fluid in the presence of a siliconesurfactant.
 2. The method according to claim 1, wherein the catalyst isan organic catalyst.
 3. The method according to claim 2, wherein theorganic catalyst is a nucleophilic nitrogen compound having basicity. 4.The method according to claim 2, wherein the organic catalyst is acyclic compound containing a nitrogen atom.
 5. The method according toclaim 2, wherein the organic catalyst is at least one selected from thegroup consisting of a cyclic amine compound, a cyclic diamine compound,a cyclic triamine compound having a guanidine skeleton, a heterocyclicaromatic organic compound containing a nitrogen atom and N-heterocycliccarbene.
 6. The method according to claim 5, wherein the organiccatalyst is any one selected from the group consisting of1,4-diazabicyclo-[2.2.2]octane, 1,8-diazabicyclo[5.4.0]undec-7-ene,1,5,7-triazabicyclo[4.4.0]dec-5-ene, diphenylguanidine,N,N-dimethyl-4-aminopyridine, 4-pyrrolidinopyridine and1,3-di-tert-butylimidazol-2-ylidene.
 7. The method according to claim 1,wherein the ring-opening polymerizable monomer is a lactide of L-formlactic acids, a lactide of D-form lactic acids, or a lactide of anL-form lactic acid and a D-form lactic acid.
 8. The method according toclaim 1, wherein the surfactant used in (A) has compatibility to boththe compressive fluid and the ring-opening polymerizable monomer.
 9. Themethod according to claim 1, wherein the surfactant used in (A) containsany one selected from the group consisting of a perfluoroalkyl group, apolydimethylsiloxane group and a polyacrylate group.
 10. The methodaccording to claim 1, wherein the silicone surfactant used in (B) is asurfactant represented by General Formula (1), (2) or (3) below:

where Me denotes a methyl group; one or two among R¹, R² and R³ eachrepresent a residue containing a C6-C30 long-chain alkyl group and theother or the others each represent a residue containing a C1-C4 loweralkyl group; and each of m and n is an integer of 1 or greaterindicating a number of repeating units,

where Me denotes a methyl group, R⁴ and R⁶ each represent a hydrogenatom or a methyl group, R⁵ represents a methylene group or an ethylenegroup, and each of m and n is an integer of 1 or greater indicating anumber of repeating units,

where at least one of R⁷ and R⁸ represents a residue containing a C6-C30long-chain alkyl group and the other represents a residue containing aC1-C4 lower alkyl group; R³ to R¹³ each represent a hydrogen atom or aC1-C4 lower alkyl group; and each of m and n is an integer of 1 orgreater indicating a number of repeating units.
 11. The method accordingto claim 1, wherein the compressive fluid is formed of carbon dioxide.12. Polymer particles obtained by a method comprising: (A) polymerizinga ring-opening polymerizable monomer to produce a polymer whilegranulating the polymer in a compressive fluid with a catalyst in thepresence of a surfactant, or (B) polymerizing an addition polymerizablemonomer to produce a polymer while granulating the polymer in acompressive fluid in the presence of a silicone surfactant.
 13. Thepolymer particles according to claim 12, wherein the polymer particleshave a molecular weight distribution Mw/Mn of 2.0 or less, where Mwdenotes a weight average molecular weight of the polymer particles andMn denotes a number average molecular weight of the polymer particles.